The present invention relates to a process for preparing carbamates, and in particular polyolefin-N-substituted-carbam tes suitable for use as gasoline additives.

It is known that during the initial operation of a new or clean internal combustion engine, a gradual increase in octane requirement (OR), i.e. the fuel octane number required for knock- free operation, increases with the build-up of combustion chamber deposits until a stable level is reached, which generally corresponds to a time when deposits remain relatively constant. The actual stable level can vary with engine design and even with individual engines of the same design.

Many additives are known which can be added to hydrocarbon fuels to attempt to prevent or reduce deposit formation or remove or modify formed deposits in the combustion chamber and adjacent surfaces, such as valves, ports and spark plugs, in order to reduce octane requirement.

Continued improvement in design of internal combustion engines, e.g., fuel injection and the like, brings changes to the atmosphere of the combustion chamber so there is a continuing need for new additives to control the problem of deposits and improve driveability which is usually related to deposits.

It is known from EP-A-414 963 and EP-A-523 278 that polyolefin-N-substituted carbamates are gasoline additives which are helpful in preventing, or reducing the accumulation of engine deposits. They may thereby be effective in controlling octane requirement increase. However, known methods of making such additives result in comparatively low yields. For example, the test used in EP-A-414 963 to determine yield was based on Basic N content before and after reaction (see EP-A-414963, Example 1) . Basic N content assessment has subsequently been found to be an invalid test for determining yield. This is due to the reaction of an alkyl chloride with one of the Basic N's in the starting amine. Alkyl chlorides result from dissociation of

chloroformates used as reagent to place a carboxyl group on one of the nitrogens in the starting amine.

It has now been found possible to prepare polyolefin-N- substituted carbamates in enchanced yield relative to the above known process.

According to the present invention there is provided a process for preparing a carbanate which comprises contacting in the presence of a base a polyolefin-secondary-amine with a chloroformate compound of the formula IV R ¹ —O— —CI (IV)

II

0 in which R-*- is a hydrocarbyl or substituted hydrocarbyl group containing up to 20 carbon atoms, thereby producing a polyolefin- N-substituted-carbamate of formula I

_&.—t :——OnoRl* ¹ (I) in which R is a polyolefin radical having an average molecular weight in the range from 500 to 9,900, R--- is a hydrocarbyl or substituted hydrocarbyl group containing up to 20 carbon atoms, and A is derived from an N-substituted amino group in which the substituent is a hydrocarbyl or substituted hydrocarbyl group containing up to 20 carbon atoms, and removing hydrogen chloride formed in producing the carbamate of formula I as a salt.

The moiety A of the polyolefin-N-sustituted carbamates of formula I is derived from an N-substituted monoamine or from a polyamine having from 2 to 10 amine nitrogen atoms. This amine can contain up to 20 carbon atoms. The hydrocarbyl and substituted hydrocarbyl groups of the amine include aliphatic, alicyclic, aromatic or hetrocyclic groups. The substituted hydrocarbyl group includes those hydrocarbyl groups substituted by one or more non-interfering atoms or substituents, including ring oxygen and keto, hydroxy, nitro, cyano, alkoxy and acyl, particularly alkanoyl. The hydrocarbyl groups are preferably relatively free of aliphatic unsaturation.

Non-limiting illustrative compounds of formula I include those wherein:

R hydrogenated ethyl phenyl-N polyisoprene ethylene-propylene phenyl ethyl-N copolymer polybutadiene cyclobutyl methyl-N polypropylene benzyl ethyl-N polybutylene vinyl isopropyl-N polyisobutylene methyl 3- (N,N-dimethyl)aminopropyl-N polyisobutylene ethyl 3-(N,N-diethyl)aminopropyl-N polyisobutylene isobutyl 2- (N,N-propyl)aminopropyl-N

polyisobutylene ethyl -N N-

The hydrocarbyl and substituted hydrocarbyl groups of ^ in formula IV may conveniently include aliphatic, alicyclic, aromatic or heterocyclic groups optionally substituted by one or more non-interfering atoms or substituents including ring-O, ring-N and keto, hydroxy, nitro, cyano, alkoxy and acyl groups. The compounds of formula IV are generally available in the art.

Preferred compounds of formual IV include those compounds wherein R- ^* - is an alkyl group containing from 1 to 10 carbon atoms, an alkenyl group containing from 2 to 7 carbon atoms, a cycloalkyl group containing from 3 to 7 ring carbons and a total of 3 to 10 carbon atoms or an aryl, aralkyl or alkaryl group containing from 6 to 10 total carbon atoms. Preferably, R ¹ is an alkenyl group containing 1 to 4 carbon atoms, such as methyl, ethyl, n-propyl, isopropyl, n-butyl or isobutyl. Preferably, R ¹ is methyl, ethyl, n-butyl or isobutyl. It will be appreciated that in cases where the polyolefin- secondary amine contains more than one nitrogen atom having a N-H

linkage, depending on the molar ratio of chlorformate: polyolefin secondary amine the moiety A may contain N-COOR ¹ groups in addition to or in place of N-H linkages in the eventual compound of formula I. Examples of such products are described in EP-A- 523 278.

The yield of the poly(olefin)-N-substituted carbamate of formula I may be as high as 70% by weight, or even 80% by weight or more.

Preferred polyolefin-N-substituted-carbamates contain at least one olefinic polymer chain and include those of the formula II

wherein R is an polyolefin radical having an average molecular weight in the range 500 to 9,900; R^ is hydrocarbyl group containing up to 20 carbon atoms; and R ² is hydrocarbyl group or a hydrocarbylaminohydrocarbyl group, each containing up to 20 total carbon atoms in the hydrocarbyl group(s) . Preferred compounds of formula I of the invention include those compounds wherein R is a polyolefin radical having an average molecular weight in the range 550 to 4,900, preferably 600 to 1300.

R--- is preferably an alkyl group containing from 1 to 10 carbon atoms, an alkenyl group containing from 2 to 7 carbon atoms, a cycloalkyl group containing from 3 to 7 ring carbon atoms and a total of 3 to 10 carbon atoms or an aryl, aralkyl or alkaryl group containing from 6 to 10 total carbon atoms. R^ is preferably an alkyl group containing 1 to 4 carbon atoms. R ² is preferably an alkyl group containing from 1 to 10 carbon atoms, an alkenyl group containing from 2 to 7 carbon atoms, a cycloalkyl group containing from 3 to 7 ring carbon atoms and a total of 3 to 10 carbon atoms or an aryl, aralkyl or alkaryl group containng from 6 to 10 total carbon atoms, or more preferably, a group of formula III

R"

/

-R' - (N-R' ) _X -N (III )

R"

R" wherein each R' is independently an alkylene group containing from 1 to 8 carbon atoms, prferably from 1 to 4 carbon atoms, more preferably propylene; and each R" is independently a hydrogen atom, a group - COOR**-, where R-^ is as defined above, provided that no N atom bears two -COOR-'- groups, or an alkyl group containing from 1 to 7 carbon atoms, preferably from 1 to 4 carbon atoms, more preferably a methyl group; and x is 0 to 23, preferably 0 to 20, more preferably 0 to 5, and advantageously 0. It is preferred for each R" independently to represent a hydrogen atom or an alkyl group of 1 to 7 carbon atoms. Preferably, when R ² is a group of formula III, each R ¹ is an alkylene group containing from 1 to 4 carbon atoms; each R" is independently an alkyl group containing from 1 to 4 carbon atoms and x is 0 to 5, e.g. 0 to 2, preferably O or 1. Especially preferred is for R ¹ to be propylene, each R" to be a methyl group and x to be from 0 to 5, preferably 0.

It is preferred for the resulting compound of formula I or II to contain a single NCOOR-*- moiety, and in order to achieve this it is preferred that the molar ratio polyolefin-secondary- amine:chloroformate compound of formula IV is greater than 1:1, e.g. in the range 1.05:1 to 1.3:1.

The polyolefin-secondary amine intermediates (including polyamines) can be prepared by reacting olefinic polymers with amines employing conventional procedures, e.g. as described in EP-A-414 963. These oil-soluble polyolefin-secondary amine intermediates have at least one polymer chain having a molecular weight in the range from 500 to 9,900 and preferably from 550 to 4,900, and particularly from 600 to 1,300, which can be saturated or unsaturated and straight or branch chain and is/are attached to a nitrogen and/or a carbon atom of the amine.

Preferred polyolefin-N-substituted-secondary-amine intermediates are polyalkylene polyamines having the structural formula V

H R" R-N-R'-(N-R') _χ -N (V)

R" R" wherein R represents a polyolefin radical having a molecular weight in the range 500 to 9,900, each R' is an alkylene radical having from 1 to 8 carbon atoms, preferably 1 to 4 carbon atoms, each R" is independently hydrogen or lower alkyl containing 1 to 7 carbon atoms and x is from 0 to 5. Preferred is a polyamine wherein R is a branch-chain polyolefin radical in the molecular weight range of 550 to 4,900, with a molecular weight range of 600 to 1300 being preferred. The polyolefins which give rise to R in formulae I, II and V are reacted with amines to form the polyolefin-N-substituted- secondary-amine intermediates of the present invention by methods which are known in the art, e.g. from U.S. Patent No. 4,357,148, and include polyolefins derived from alkanes or alkenes with straight or branched chains, which may nor may not have aromatic or cycloaliphatic substituents, for instance, groups derived from polymers or copolymers of olefins which may or may not have a double bond. Examples of non-substituted alkenyl and alkyl groups are polyethylene groups, polypropylene groups, polybutylene groups, polyisobutylene groups, polyethylene- polypropylene groups, polyethylene-polyalphamethyl styrene groups and the corresponding groups without double bonds. Particularly preferred are polypropylene and polyisobutylene groups. Polyisobutylene groups are conveniently effective. The R" group can be hydrogen but is preferably lower alkyl, i.e. containing up to 7 carbon atoms and more preferably an alkyl group containing from 1 to 4 carbon atoms, e.g. methyl, ethyl, propyl or butyl.

Suitable amine reactants are broadly referred to as (poly)amines to include both polyamines and monoamines as hereinafter more fully described. The (poly)amines used to react

with the polyolefins to form the polyolefin-N-substituted- secondary-amine intermediates include aliphatic, alicyclic, aromatic or heterocyclic monoamines or polyamines. A variety of such amines is well documented in the art including U.S. Patent No. 4,191,537. The amines can contain other non-reactive substitutes. Suitable substituents for such amines include alkyls such as methyl, ethyl, propyl, butyl, isobutyl, pentyl, hexyl and octyl; alkenyls such as propenyl, isobutenyl, hexenyl and octenyl; hydroxyalkyls, such as 2-hydroxyethyl, 3-hydroxy- propyl, hydroxy-isopropyl and 4-hydroxybutyl; ketoalkyls, such as 2-ketopropyl and 6-ketooctyl; alkoxy and lower alkenoxyalkyls, such as ethoxyethyl, ethoxypropyl, propoxyethyl, propoxypropyl, 2- (2-ethoxyethoxy)ethyl, and acyl groups such as propionyl and acetyl groups. Preferred substituents are C^-Cg alkyl groups. Heterocyclic amines can be saturated, unsaturated and substituted or unsubstituted. Suitable heterocyclic amines include piperazines, such as 2-methylpiperazine, N-(2-hydroxy- ethyl)-piperazine, 1,2-bis- (N-piperazinyl)ethane, and N,N'-bis- (N-piperazinyl)piperazine, 2-methylimidazoline, 3-amino- piperidine, 2-aminopyridine, 2- (3-aminoethyl)-3-pyrroline,

3-aminopyrrolidine, N- (3-aminopropyl)morpholine, and the like. Among the heterocyclic compounds, the piperazines are preferred.

The amine reactants include mixtures of compounds, such as mono and polysubstituted polyamines or isomers. The polyamines used to form the preferred polyolefin polyamine intermediate compounds of this invention include low molecular weight aliphatic polyamines such as ethylene diamine, diethylene triamine, triethylene tetramine, propylene diamine, butylene diamine, trimethyl trimethylene diamine, tetramethylene diamine, diaminopentane or pentamethylene diamine, hexamethylene diamine, heptamethylene diamine, diaminooctane, decamethylene diamine, and higher homologues up to 18 carbon atoms.

Compounds possessing triamine as well as tetramine and pentamine groups are applicable for use because these can be prepared from technical mixtures of polyethylene polyamines, which may offer economic advantages.

The polyamine starting materials from which the polyamine groups can be derived can also be a cyclic polyamine, for instance, the cyclic polyamines formed when aliphatic polyamines with nitrogen atoms separated by ethylene groups are heated in the presence of hydrogen chloride.

Monoamines which can be used to prepare the polyolefin secondary-amines include monoamines in which the hydrocarbyl groups contain from 1 to 14 carbon atoms. For example, each hydrocarbyl group is independently selected from an alkyl group containing from 1 to 10 carbon atoms, an alkenyl group containing from 2 to 7 carbon atoms, a cycloalkyl group containing from 3 to 7 ring carbon atoms and a total of 3 to 10 carbon atoms, and aryl, aralkyl and alkaryl groups containing from 6 to 10 total carbon atoms. Preferably, the hydrocarbyl groups are independently selected from an alkyl group containing from 1 to 4 carbon atoms, e.g., ethyl or propyl.

The reaction between compound of formula IV and polyolefin- secondary amine is preferably effected at a temperature less than 90°C, preferably from 60°C to 70°C, in the presence of a solvent and a base. Reaction may conveniently be effected at atmospheric pressure. A solvent having should have a boiling point that is high enough so that the solvent does not boil off during the reaction and low enough to be able to separate the solvent from the eventual product by distillation. A convenient solvent for use in the method of this invention has a boiling point in the range from about 130°C to about 150°C. For example, xylenes are an appropriate solvent and have boiling points in the range 137 to 144°C.

The polyolefin carbamate product of formula I is recovered by conventional techniques, such as drying by stripping water or by using anhydrous sodium sulfate.

The solvent is usually removed, e.g., by stripping, for neat analysis. However, for practical applications some or all of the solvent can be retained as a diluent. Small amounts of polyolefin-secondary-unreacted amine intermediate need not be removed from the product as the presence

thereof does not interfere with the usefulness of the product of formula I. Unreacted amine can aid in the effects of the • polyolefin-N-substituted-carbamates of the invention by acting as a carrier, assisting in enhancing the preventing, removing or retarding of engine deposits (particularly when the carbamate is of methyl or a non-beta hydrogen group) or by providing their known fuel detergents properties.

The function of the base during the reaction is to neutralize HC1. This is because HC1 catalyzes the decomposition of chloroformates to alkyl chlorides. Formation of alkyl chlorides is undesirable since they alklate the Basic N moieties in the polyolefin-secondary-amine. The alkyl chlorides may thereby prevent N-H moieties of the starting amine reactant from reacting as desired with the cloroformates so as to form an N- COOR ¹ moiety. The alkyl chlorides may also react with other Basic N moieties, e.g. -N(CH3)2 groups, where it is preferred that such other Basic N moieties should not react at all during the process. This is because it may be desired to have a remaining Basic N in the additive to neutralize acids in the gasoline or acids resulting from combustion of the gasoline.

Accordingly, the base used in the method of this invention is one having a strong enough basicity to neutralize HC1 and a low enough nucleophilicity so as not to react with chloroformate. Such base is needed since it will neutralize the HC1 and thus prevent the HC1 from catalyzing the disassociation of chloroformates. At the same time such a base will not itself react with the chloroformate. Suitable bases include basic alkali metal compounds, such as alkali metal carbonates, bicarbonates or alkanoates, e.g. acetates, or mixtures thereof, e.g., sodium or potassium carbonate, sodium or potassium bicarbonate, sodium acetate, or mixtures thereof.

Sodium and potassium bicarbonates are preferred bases since they result in less solid waste, a solid waste having a low pH and a higher yield of product. The base is preferably granular in form and more preferably less than about 100 microns. The less the diameter the higher the surface area. Higher surface

areas permit smaller reaction vessels. Preferably the salt waste produced has a pH less than about 10. Such low pH levels are deemed non-hazardous in some environmental regulations. Preferably the reaction produces less than about 10% by weight of the waste based on the weight of the waste and carbamate produced. The term "waste" includes alkali metal chloride, such as NaCl, and excess unreacted base, e.g., sodium bicarbonate.

The invention will be further understood from the following illustrative example of the invention and comparative example not of the invention. Here and elsewhere in this specification, the term "average molecular weight" signifies number average molecular weight (Mn) .

Comparative Example A - No Base Present During Reaction (corresponds to first compound of Example 2 of EP-A-414 963) Preparation of a Compound of Formula I with R- ^* -= methyl; R = polyisobutylene of 900 average molecular weight; and A = N-CH ₇ CH _? CH _? N(CH^) _?

Five Hundred grams of polyisobutylene-NH- (CH2) 3-N(CH3)2 (80.5% non-volatile, 19.5% xylenes, and containing 1.50% basic nitrogen) (0.4 mol) were charged to a 1000 ml, round-bottomed flask equipped with a air-driven stirrer, reflux condenser, thermometer, and addition funnel. To the addition funnel were added 34.4 grams (0.36 mol) of methyl chloroformate and 21 ml of toluene. The toluene solution was added dropwise at ambient temperature (20°C) to the round-bottomed flash with stirring. The addition took about 10 minutes with an increase of 36°C in reaction temperature. The reaction flask was heated to 160°C after the addition was completed and maintained at that temperature for 1 hour. The addition funnel was removed and replaced with a powder funnel. Through this latter funnel was added a solution of 44.0 grams of sodium bicarbonate in 177 grams of water. Upon completion of the addition, the flask was heated to 100°C for one hour.

The contents of the reaction flask were transferred to a 2000 ml separatory funnel where the layers were separated and the lower water layer was removed. The remaining layer was treated

three times with 150 ml of water. The water was removed and the contents of the funnel were transferred to a 2000 ml Erlenmeyer flask. Five hundred ml of toluene were added to the flask together with anhydrous sodium sulfate. After one hour of stirring, the contents of the Erlenmeyer flask were filtered and solvent removed by rotary evaporation. Evaluation of the neat material revealed a 60% molar conversion. Example 1 - Base Present During Reaction

A compound of formula I with R ¹ = methyl; R = polyisobutylene of 900 average molecular weight; and A = N- CH2CH2CH2N(CH3)2, was prepared according to the invention as follows.

Five Hundred grams of polyisobutylene-NH-(CH2)3~N(CH3) ₂ (80.5% non-volatile, 19.5% xylenes, and containing 1.50% basic nitrogen) (0.4 mol) were charged to a 1000 ml, round-bottomed flask equipped with an air-driven stirrer, reflux condenser, thermometer, and powder funnel. Through the powder funnel was added 44.0 grams of dry sodium bicarbonate. The powder funnel was removed and an addition funnel was positioned. To the addition funnel was added 34.4. grams (0.36 mol) of methyl chloroformate and 21 ml of toluene. The toluene solution was added dropwise at 70°C to the round-bottomed temperature. Upon completion of the addition, the reaction flask was maintained at 70°C for 1 hour. The reaction mixture was then further treated as in Comparative Example A except that the 44.0 grams of sodium bicarbonate were omitted from the 177 grams of water. Evaluation of the resulting neat material revealed a 85% molar conversion.

* Waste contains NaCl and unreacted base in the case of Example 1.

Results of these tests demonstrate that the process of the invention for making poly(olefin)-N-substituted-carbamates is very useful in significantly increasing yield and reducing solid waste production, and reducing the pH of the resulting waste. The small amount of waste that is produced is in a form suitable for easy and environmentally safe disposal.